Vehicle power module assembly

ABSTRACT

A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/018,544filed Jun. 26, 2018, now U.S. Pat. No. 11,317,546 issued Apr. 26, 2022,the disclosure of which is hereby incorporated in its entirety byreference herein.

TECHNICAL FIELD

The present disclosure relates to vehicle power module assemblies.

BACKGROUND

A vehicle power unit may be formed by stacking and connecting a numberof power modules based on vehicle power requirements. Pins from thepower modules interface with adjacent power electronics.

SUMMARY

A vehicle power module assembly includes a first power module and asecond power module. The first power module includes a first lockfeature extending from a lower portion of a first minor side at a firstcentral axis. The second power module includes a second lock feature atan upper portion of a second minor side at a second central axis. Thelock features are sized for interlock with one another to secure thepower modules to one another. The first lock feature may be a loopelement defining a through-hole and the second lock feature may be awedge. The through-hole may be sized for the wedge to extend therein andto interlock the first power module and the second power module to oneanother. The first lock feature may be a flexible hook element and thesecond lock feature may be a slot. The slot may be sized to receive aportion of the hook element to interlock the first power module and thesecond power module to one another. The first power module may furtherinclude a second first lock feature extending from a lower portion of afirst major side. The second power module may further include anothersecond lock feature at an upper portion of a second major side. Thesecond first lock feature may be arranged with the another second lockfeature such that interlocking of corresponding lock features applies aclamping force sufficient to create a sealed relationship between thefirst power module and the second power module. The lock features may bearranged upon respective minor sides at respective central axes suchthat a third power module having a design substantially identical to thefirst power module or the second power module may be secured in a stackto the first power module or the second power module. The first powermodule may further include an extension extending about and spacedinward from a perimeter of a lower surface portion of the first powermodule. The second power module may further include a groove extendingabout and spaced inward from a perimeter of an upper surface portion ofthe second power module. The extension and groove may be arranged withone another to align a first coolant channel of the first power modulein substantial registration with a second coolant channel of the secondpower module. The first power module or the second power module mayfurther include two pairs of coolant channels extending therethrough anda coolant cavity connecting two of the two pairs of coolant channelssuch that coolant flow is directed across a heat generating componentdisposed within the power module.

A vehicle power module assembly includes a first power module and asecond power module. The first power module includes a first pair ofopposing major sides, each of the first pair of opposing major sidesincluding a flange extending therefrom and each flange including a graspelement. The second power module includes a second pair of opposingmajor sides and an upper portion spaced from a lower portion to define apair of grooves therebetween and each located adjacent to one of thesecond pair of opposing major sides. Each groove extends a length of oneof the major sides and each groove is sized to receive one of the graspelements such that one of the first pair of opposing major sides issubstantially flush with one of the second pair of opposing major sideswhen the first power module and the second power module are secured toone another. The second power module may further include an upperportion having at least one side face defining a first plane offset froma second plane defined by one of the first pair of opposing major sidesof the first power module. The flanges of the first power module may bespaced from one another to define a cavity sized to at least partiallyreceive the upper portion of the second power module therebetween. Thefirst power module may include at least a first coolant channelextending therethrough. The second power module may include at least asecond coolant channel therethrough. The grooves and grasp elements maybe arranged with one another such that the first coolant channel and thesecond coolant channel are in substantial registration with one anotherwhen the first power module and the second power module are secured toone another. The grooves and grasp elements may be arranged with oneanother such that there are no fasteners projecting externally from thepower modules when secured to one another. The first power module or thesecond power module may further include two pairs of coolant channelsextending therethrough and a coolant cavity connecting two of the twopairs of coolant channels such that coolant flow is directed across aheat generating component disposed within the power module. The assemblymay further include a third power module. The first power module, thesecond power module, and the third power module may each include asubstantially identical structure such that the third power module maybe mounted to the first power module or the second power module.

A vehicle power module assembly includes a first power module and asecond power module. The first power module includes a lower portiondefining a perimeter sidewall, a cavity within the perimeter sidewall,and an inner extension extending about a cavity perimeter spaced inwardfrom the perimeter sidewall. The second power module includes an upperportion spaced from a lower portion to define a groove therebetweenextending about a perimeter of the upper portion. The upper portion ofthe second power module is sized for disposal within the cavity of thelower portion of the first power module such that the inner extensionsits within the groove to align the first power module and the secondpower module for securement to one another. The groove of the secondpower module may be sized to receive sealant to seal the inner extensiontherein. The first power module may further include a first coolantchannel. The second power module may further include a second coolantchannel. The first power module and the second power module may besecured to one another such that the first coolant channel is in fluidcommunication with the second coolant channel and sealed to preventleakage of coolant traveling within one of the coolant channels. Theinner extension may sit within the groove such that a first side of thefirst power module is substantially flush with a second side of thesecond power module. The inner extension may sit within the groove suchthat no fasteners project externally to the first power module or thesecond power module. The first power module may include one or moreswitching units disposed therein. The first power module may furtherdefine two pairs of coolant channels and a coolant cavity fluidlyconnecting two of the two pairs of coolant channels. The coolant cavitymay be arranged within the first power module such that coolant disposedtherein may travel across the one or more switching units to managethermal conditions thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic diagram illustrating an example of an electrifiedvehicle.

FIG. 1B is a circuit diagram illustrating an example of a power supplydevice coupled to a power source and a load.

FIG. 2A is an exploded perspective view of an example of two powermodules.

FIG. 2B is a perspective view of the two power modules of FIG. 2A shownmounted to one another.

FIG. 2C is a first perspective view of a portion of one of the two powermodules of FIG. 2A showing a coolant channel configuration.

FIG. 2D is a second perspective view of the portion of the one of thetwo power modules of FIG. 2C.

FIG. 3A is an exploded upper perspective view of an example of two powermodules.

FIG. 3B is a perspective view of the two power modules of FIG. 3A shownmounted to one another.

FIG. 3C is an exploded lower perspective view of the two power modulesof FIG. 3A

FIG. 4A is an exploded perspective view of an example of two powermodules.

FIG. 4B is a perspective view of the two power modules of FIG. 4A shownmounted to one another.

FIG. 4C is a top plan view of a portion of one of the power modules ofFIG. 4A.

FIG. 4D is a front view, in cross-section, of FIG. 4B showing the twopower modules mounted to one another.

FIG. 5A is an exploded perspective view of an example of two powermodules.

FIG. 5B is a perspective view of the two power modules of FIG. 5A shownmounted to one another.

FIG. 5C is a front view, in cross-section, of FIG. 5B showing the powermodules of FIG. 5A mounted to one another.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It is to beunderstood, however, that the disclosed embodiments are merely examplesand other embodiments can take various and alternative forms. Thefigures are not necessarily to scale; some features could be exaggeratedor minimized to show details of particular components. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a representative basis forteaching one skilled in the art to variously employ the presentdisclosure. As those of ordinary skill in the art will understand,various features illustrated and described with reference to any one ofthe figures can be combined with features illustrated in one or moreother figures to produce embodiments that are not explicitly illustratedor described. The combinations of features illustrated providerepresentative embodiments for typical applications. Variouscombinations and modifications of the features consistent with theteachings of this disclosure, however, could be desired for particularapplications or implementations.

FIG. 1A illustrates an example of an electrified vehicle, referred to asan electrified vehicle 12 herein. In this example, the electrifiedvehicle is shown as a plug-in hybrid electric vehicle (PHEV). Theelectrified vehicle 12 may include one or more electric machines 14mechanically coupled to a gearbox or hybrid transmission 16. Each of theelectric machines 14 may be capable of operating as a motor and agenerator. In addition, the hybrid transmission 16 is mechanicallycoupled to an engine 18 and the hybrid transmission 16 is mechanicallycoupled to a drive shaft 20 that is mechanically coupled to a set a setof wheels 22. The electric machines 14 may provide propulsion anddeceleration capability when the engine 18 is turned on or off. Theelectric machines 14 may also act as generators and provide fuel economybenefits by recovering energy that would normally be lost as heat in afriction braking system. The electric machines 14 may also reducevehicle emissions by allowing the engine 18 to operate at more efficientspeeds and allowing the electrified vehicle 12 to be operated inelectric mode with the engine 18 off under certain conditions. Theelectrified vehicle 12 may also be a battery electric vehicle (BEV), afull hybrid electric vehicle (FHEV), a mild hybrid electric vehicle(MHEV), or other vehicle utilizing an electric drive and/or an electricmotor. In a BEV configuration, the engine 18 may not be present.

A battery pack or traction battery 24 stores energy that may be used bythe electric machines 14. The traction battery 24 may provide a highvoltage direct current (DC) output. A contactor module 42 may includeone or more contactors to isolate the traction battery 24 from ahigh-voltage bus 52 when opened and to connect the traction battery 24to the high-voltage bus when closed. The high-voltage bus may includepower and return conductors for carrying current. The contactor module42 may be located adjacent to or within the traction battery 24. One ormore power electronics modules 26 (which may also be referred to as aninverter or power module) may be electrically coupled to thehigh-voltage bus. The power electronics modules 26 are electricallycoupled to the electric machines 14 and provide the ability tobi-directionally transfer energy between the traction battery 24 and theelectric machines 14. For example, a traction battery 24 may provide aDC voltage while the electric machines 14 may operate with a three-phasealternating current (AC). The power electronics module 26 may convertthe DC voltage to a three-phase AC current to operate the electricmachines 14. In a regenerative mode, the power electronics module 26 mayconvert the three-phase AC current from the electric machines 14 actingas generators to the DC voltage compatible with the traction battery 24.

In addition to providing energy for propulsion, the traction battery 24may provide energy for other vehicle electrical systems. The electrifiedvehicle 12 may include a DC/DC converter module 28 that converts thehigh voltage DC output from the high-voltage bus to a low-voltage DClevel of a low-voltage bus that is compatible with low-voltage loads 45.An output of the DC/DC converter module 28 may be electrically coupledto an auxiliary battery 30 (e.g., a 12V battery) for charging theauxiliary battery 30. The low-voltage loads 45 may be electricallycoupled to the auxiliary battery 30 via the low-voltage bus. One or morehigh-voltage electrical loads 46 may be coupled to the high-voltage bus.The high-voltage electrical loads 46 may have an associated controllerthat operates and controls the high-voltage electrical loads 46 whenappropriate. Examples of high-voltage electrical loads 46 may be a fan,an electric heating element and/or an air-conditioning compressor.

In a PHEV embodiment, the electrified vehicle 12 may be configured torecharge the traction battery 24 via an external power source 36. Theexternal power source 36 may include a connection to an electricaloutlet. The external power source 36 may be electrically coupled to acharge station or an electric vehicle supply equipment (EVSE) 38. Theexternal power source 36 may be an electrical power distribution networkor grid as provided by an electric utility company. The EVSE 38 mayprovide circuitry and controls to regulate and manage the transfer ofenergy between the external power source 36 and the electrified vehicle12. The external power source 36 may provide DC or AC electric power tothe EVSE 38. The EVSE 38 may have a charge connector 40 for coupling toa charge port 34 of the vehicle 12. The charge port 34 may be any typeof suitable port configured to transfer power from the EVSE 38 to thevehicle 12. The charge port 34 may be electrically coupled to anon-board power conversion module 32 which may operate as a charger. Thepower conversion module 32 may condition the power supplied from theEVSE 38 to provide appropriate voltage and current levels to thetraction battery 24 and the high-voltage bus. The power conversionmodule 32 may interface with the EVSE 38 to coordinate the delivery ofpower to the electrified vehicle 12. The EVSE connector 40 may have pinsto mate with corresponding recesses of the charge port 34.

One or more wheel brakes 44 may be provided for decelerating theelectrified vehicle 12 and preventing motion of the electrified vehicle12. The wheel brakes 44 may be hydraulically actuated, electricallyactuated, or some combination thereof. The wheel brakes 44 may be a partof a brake system 50. The brake system 50 may include other componentsto operate the wheel brakes 44.

FIG. 1B is a circuit diagram illustrating an example of a power supplydevice 54 coupled to a power source 56 and a load 58. The power supplydevice 54 may convert DC electrical current into AC electrical current.The power supply device 54 may be utilized in an electric drive systemof a vehicle, such as the electrified vehicle 12 described above. Thepower source 56 may be coupled to the power supply device 54 in order todrive the load 58. The power source 56 may be a battery, such as thetraction battery 24 described above, and the load 58 may be an electricmachine, such as one of the electric machines 14 described above. Thepower source 56 may further comprise a high voltage battery that iscoupled to a voltage converter (not shown). The power supply device 54may include a power assembly or power module 60. The power module 60 maydeliver electrical power to the load 58. The power module 60 may be aninverter or an inverter assembly to convert DC electrical current intoAC electrical current.

The power module 60 may include inverting circuitry and heat generatingcomponents such as a plurality of switching units 64. The power module60 may be an inverter that includes any number of switching units and isnot limited to the number of switching units shown in FIG. 1A. Each ofthe switching units 64 may include a transistor 66 arranged antiparallelwith a diode 68. In one example, the transistor 66 may be an insulatedgate bipolar transistor (IGBT). The switching units 64 may providealternating current to the load 58. The power supply device 54 mayinclude a linking capacitor 72 disposed between the power source 56 andthe power module 60. The linking capacitor 72 may absorb ripple currentsgenerated at the power module 60 or the power source 56, and stabilizethe DC-link voltage, Vo, for power module 60 control. The linkingcapacitor 72 may be arranged to limit voltage variation at an input ofinverting circuitry due to ripple currents generated by the invertingcircuitry in the power module 60 or a battery, such as a tractionbattery, that may comprise the power source 56. Alternatively, thelinking capacitor 72 may be configured to couple one or a plurality ofinverters to a power source.

FIG. 2A is a partially exploded perspective view illustrating an exampleof a portion of a power module assembly, referred to generally as apower module assembly 100 herein. The power module assembly 100 includesa first power module 106 and a second power module 108 shown separatedfrom one another in FIG. 2A. Each power module may include one or morecoolant channels extending through a respective power module. Forexample, the first power module 106 may include one or more coolantchannels 110 and the second power module 108 may include one or morecoolant channels 111.

Each of the coolant channels 110 and each of the coolant channels 111may be oriented within a respective power module at a location adjacentheat generating components to assist in managing thermal conditionsthereof. For example, each of the coolant channels 110 and each of thecoolant channels 111 may be located adjacent one or more switching unitsor a power stage. Each of the coolant channels 110 and each of thecoolant channels 111 may also assist in orienting the first power module106 and the second power module 108 for mounting to one another. Each ofthe coolant channels 110 and each of the coolant channels 111 may be influid communication with a thermal management system (not shown) forcoolant to be delivered and removed therefrom.

While two power modules (the first power module 106 and the second powermodule 108) are shown in FIGS. 2A and 2B, it is contemplated that thepower module assembly 100 may include two or more stacked power modulesbased on vehicle power requirements. A structural design of each of thefirst power module 106 and the second power module 108 may be utilizedin each of a stack of a plurality of power modules without needing todesign additional power module embodiments.

Each of the first power module 106 and the second power module 108 mayinclude fastening features or locking features to facilitate securementto and alignment with one another. For example, the first power module106 may include a pair of first wedge elements 114 and a pair of firstloop elements 116. In FIGS. 2A and 2B only one of the pair of firstwedge elements 114 and one of the pair of first loop elements 116 isshown due to an orientation of the first power module 106.

The second power module 108 may include a pair of second wedge elements118 and a pair of second loop elements 120. In FIGS. 2A and 2B only oneof the pair of second wedge elements 118 and one of the pair of secondloop elements 120 is shown due to an orientation of the second powermodule 108.

Each of the pair of first wedge elements 114 and each of the pair offirst loop elements 116 may be located at a central axis 117 of one ofeach of a pair of first minor sides 119. For example, each of the pairof first wedge element 114 and each of the pair of first loop elements116 may be spaced equidistant from respective corners of the first powermodule 106. It is contemplated that each of the pair of first wedgeelements 114 and each of the pair of first loop elements 116 may belocated on an axis other than the central axis 117, such as an axisspaced between the central axis 117 and one of the corners of the firstpower module 106. A location of each of the pair of first wedge elements114 and each of the pair of first loop elements 116 may be based on adesired clamping force to promote a sealed relationship between thepower modules to facilitate coolant flow between the coolant channels.For example, a particular power module may have optimal operatingconditions relating to a coolant flow rate and coolant pressure. Thelocation of the wedges elements and loop elements may be selected toobtain a clamping force between the power modules to maintain thedesired coolant flow rate and coolant pressure.

In FIGS. 2A and 2B, only one of the pair of first minor sides 119 isshown due to an orientation of the first power module 106. Each of thepair of second wedge elements 118 and each of the pair of second loopelements 120 may be located at a central axis 121 of one of each of apair of second minor sides 123. For example, each of the pair of secondwedge elements 118 and each of the pair of second loop elements 120 maybe spaced equidistant from respective corners of the second power module108. In FIGS. 2A and 2B, only one of the pair of second minor sides 123is shown due to an orientation of the second power module 108.

Each of the pair of first loop elements 116 may be sized to receive oneof the pair of second wedge elements 118 to align and secure the firstpower module 106 to the second power module 108 as shown in FIG. 2B.Each of the wedge elements and each of the loop elements may be arrangedwith wedge elements and loop elements of the other of the power modulesto secure the power modules to one another to facilitate a sealedrelationship between the first power module 106 and the second powermodule 108 and to prevent coolant leakage.

The first power module 106 and the second power module 108 may includeadditional features to assist in aligning respective coolant channelswith one another and to assist in aligning respective fastening featureswith one another. For example, the first power module 106 may include afirst groove 124 at an upper portion and the second power module 108 mayinclude a second groove 126 at an upper portion. The first power module106 may include a first extension 128 at a lower surface and the secondpower module 108 may include a second extension 130 at a lower portion.Each extension may be sized to sit within a respective groove. Each ofthe grooves may be arranged with a respective extension to assist inaligning the coolant channels 110 of the first power module 106 insubstantial registration with the coolant channels 111 of the secondpower module 108.

It is contemplated that a third power module (not shown) may include astructural design substantially identical to one of the first powermodule 106 or the second power module 108 for securement to the firstpower module 106 or the second power module 108 in a stack. For example,the third power module may include fastening features for alignment withcorresponding fastening features of the first power module 106 or thesecond power module 108. The structural design of the first power module106 and the second power module 108 provides flexibility to utilizevarious numbers of power modules in a stack based on vehicle powerrequirements, e.g. higher power requirements may use two or more powermodules.

FIGS. 2C and 2D illustrate an example of an internal structure of thefirst power module 106 relating to the coolant channels 110. In FIGS. 2Cand 2D a first pair of the coolant channels 110 is referred to as afirst pair of coolant channels 110′ and a second pair of the coolantchannels 110 is referred to as a second pair of coolant channels 110″for clarity. The first power module 106 may include a frame 129 forretaining electrical components, such as a power stage 132. The powerstage 132 may include one or more switching units that generate heatduring operation. The frame 129 may define a coolant cavity 136 on eachside. Each of the coolant cavities 136 fluidly connects one or the firstpair of coolant channels 110′ or the second pair of coolant channels110″. For example, each of the coolant cavities 136 may be arranged withrespective coolant channels such that coolant flows across the powerstage 132 as represented by arrows 138. It is contemplated that each ofthe coolant cavities 136 may have various shapes to promote desiredcoolant flow across or adjacent the power stage 132.

FIGS. 3A through 3C show another example of a power module assembly,referred to generally as a power module assembly 150 herein. The powermodule assembly 150 may include a first power module 152 and a secondpower module 154. Each of the first power module 152 and the secondpower module 154 include fastening features, locking features, and/oralignment features to assist in mounting the power modules to oneanother, to assist in positioning one or more coolant channels of eachpower module in substantial registration with coolant channels of theother of the power modules, and to facilitate a sealed relationshipbetween the power modules. The first power module 152 may include one ormore coolant channels 153 and the second power module 154 may includeone or more coolant channels 155.

Each of the one or more coolant channels 153 and each of the one or morecoolant channels 155 may be oriented within a respective power module ata location adjacent heat generating components to assist in managingthermal conditions thereof. For example, each of the one or more coolantchannels 153 and each of the one or more coolant channels 155 may belocated adjacent one or more switching units or a power stage. Inanother example, a coolant cavity may be defined between respectivepairs of coolant channels to direct coolant across the heat generatingcomponent as described in relation to FIGS. 2C and 2D.

In one example of fastening features, the first power module 152 mayinclude one or more first slots 162 located on one or both of a pair ofpower module minor sides 164 and one or both of a pair of power modulemajor sides 166. Each of the one or more first slots 162 may be locatedat a central axis 170 of a respective power module minor side 164 or acentral axis 171 of a respective power module major side 166. In FIGS.3A and 3B, only two of the first slots 162, one of each of the pair ofpower module minor sides 164, and one of each of the pair of the powermodule major sides 166 are shown due to an orientation of the firstpower module 152.

Each of the central axes 170 may be located at a region substantiallyequidistant from each of two adjacent corners of the respective powermodule. The first power module 152 may further include a first hookelement 172 located on one or both of the power module minor sides 164and one or both of the power module major sides 166. Each of the firsthook elements 172 may be flexible and include a hook 173 sized forinserting within a slot of a power module located below and as furtherdescribed herein. Each of the first hook elements 172 may be located ata respective central axis 170 aligned with a respective one of the oneor more first slots 162.

The second power module 154 may include one or more second slots 176located on one or both of two power module minor sides 178 and one orboth of two power module major sides 180. Each of the one or more secondslots 176 may be located at a respective central axis 179 or a centralaxis 181 and each may be sized to receive one of the hooks 173 to securethe first power module 152 to the second power module 154. The secondpower module 154 may further include a second hook element 182 locatedon one or both of the two power module minor sides 178 and one or bothof the two power module major sides 180. Each of the second hookelements 182 may be flexible and include a hook 183 sized for insertingwithin a slot of a power module located below the second power module154. Alternatively, each hook 183 may be sized for grasping a portion ofa supporting surface, such as a tray or support structure (not shown).Each of the second hook elements 182 may be located at a respectivecentral axis 179 or central axis 181 aligned with a respective one ofthe one or more second slots 176.

It is contemplated that each of the slots and hook elements may belocated on an axis other than the central axis 170 or the central axis171, such as an axis spaced between a respective central axis and therespective power module corners. A location of each of the slots andhook elements may be based on a desired clamping force to promote asealed relationship between the power modules to facilitate coolant flowbetween the coolant channels. For example, a particular power module mayhave optimal operating conditions relating to a coolant flow rate andcoolant pressure. The location of the slots and hook elements may beselected to obtain a clamping force between the power modules tomaintain the desired coolant flow rate and coolant pressure.

In one example of alignment features, an upper portion of the firstpower module 152 may include a first groove 184 and an upper portion ofthe second power module 154 may include a second groove 186. Each of thegrooves may extend about and may be spaced inward from a perimeter ofthe upper portion of a respective power module. A lower portion of thefirst power module 152 may include a first extension 188 and a lowerportion of the second power module 154 may include a second extension190. Each of the extensions of the first power module 152 and the secondpower module 154 may extend about and may be spaced inward from aperimeter of the lower portion of a respective power module.

Each of the grooves and extensions may be located upon a respectivepower module to assist in aligning fastening features of the respectivepower modules for securement to one another and to assist in aligningcorresponding coolant channels for fluid communication therebetween. Forexample, the second groove 186 and the first extension 188 may bearranged with one another such that the first extension 188 rests withinthe second groove 186 when the first power module 152 and the secondpower module 154 are secured to one another. The arrangement between thefirst extension 188 and the second groove 186 may also assist inaligning central axes 170 and central axes 171 of the first power module152 with corresponding central axes 179 and central axes 181 of thesecond power module 154. Alignment of the central axes further assistsin aligning respective hook elements for insertion within respectiveslots to secure the first power module 152 and the second power module154 with one another. Each of the grooves may be sized to receive asealant material to assist in securing a respective extension within arespective groove.

It is contemplated that a third power module (not shown) may include astructural design substantially identical to one of the first powermodule 152 or the second power module 154 for securement to the firstpower module 152 or the second power module 154 in a stack. For example,the third power module may include fastening features for alignment withcorresponding fastening features of the first power module 152 or thesecond power module 154. The structural design of the power modulesprovides flexibility to utilize a number of power modules in a stackbased on vehicle power requirements, e.g. higher power requirements mayuse two or more power modules.

FIGS. 4A and 4B show another example of a power module assembly,referred to generally as a power module assembly 200 herein. The powermodule assembly 200 may include a first power module 202 and a secondpower module 204 each having fastening features and alignment features.The first power module 202 may include a pair of first minor sides 208and a pair of first major sides 210. The second power module 204 mayinclude a pair of second minor sides 212 and a pair of second majorsides 214. The first power module 202 may include a pair of first sidegrooves 218 extending a length of one of the pair of first major sides210. The second power module 204 may include a pair of second sidegrooves 220 extending a length of one of the pair of second major sides214.

The first power module 202 may include one or more coolant channels 221and the second power module 204 may include one or more coolant channels222. Each of the coolant channels may be located adjacent heatgenerating components (not shown) included within a respective powermodule. For example, each of the one or more coolant channels 221 andeach of the one or more coolant channels 222 may be located adjacent oneor more switching units or a power stage. In another example, a coolantcavity may be defined between respective pairs of coolant channels todirect coolant across the heat generating component as described inrelation to FIGS. 2C and 2D.

The first power module 202 may include a pair of first flanges 224 eachextending from one of the first major sides 210 and defining a cavity225 therebetween. Each of the pair of first flanges 224 may be flexibleand include a first grasp element 226. The first power module 202 mayinclude a first upper portion 228 offset from a first lower portion 229to define each of the pair of first side grooves 218 therebetween. Forexample, a pair of side faces 227 of the first upper portion 228 mayeach define a first upper plane offset from a first lower plane definedby a respective one the pair of first major sides 210 as furtherillustrated in FIG. 4C. A cross-sectional area of an upper surface ofthe first upper portion 228 may be less than a cross-sectional area ofthe first lower portion 229 to assist in facilitating securement toanother power module, such as the second power module 204.

The second power module 204 may include a pair of second flanges 230each extending from one of the second major sides 214 and defining acavity 231 therebetween. Each of the pair of second flanges 230 may beflexible and include a second grasp element 232. The second power module204 may include a side face of a second upper portion 234 offset from aside face of one of the second flanges 230. For example, each of twoside faces of the second upper portion 234 may define a second upperplane offset from a second lower plane defined by respective first majorsides 210 and first flanges 224.

FIG. 4D illustrates detail of an example of the fastening features andthe alignment features of the power module assembly 200. As mentionedabove, each of the first flanges 224 may be of a flexible material suchthat each of the first flanges 224 may spread outward of the secondupper portion 234 to position each of the first grasp elements 226 forinterlock within a respective second side groove 220 to secure the firstpower module 202 to the second power module 204. In this example, thegrooves and grasp elements are arranged with one another such that thereare no fasteners projecting externally from the power modules whensecured to one another. Each of the first grasp elements 226 may besized to rest within the respective second side groove 220 such that thesecond upper portion 234 is at least partially disposed within thecavity 225.

It is contemplated that a third power module (not shown) may include astructural design substantially identical to one of the first powermodule 202 or the second power module 204 for securement to the firstpower module 202 or the second power module 204 in a stack. For example,the third power module may include fastening features for alignment withcorresponding fastening features of the first power module 202 or thesecond power module 204. The structural design of the power modulesprovides flexibility to utilize a number of power modules in a stackbased on vehicle power requirements, e.g. higher power requirements mayuse two or more power modules.

FIGS. 5A and 5B show another example of a power module assembly,referred to generally as a power module assembly 250 herein. The powermodule assembly 250 may include a first power module 252 and a secondpower module 254. Each of the first power module 252 and the secondpower module 254 may include fastening features and alignment featuresto assist in securing the first power module 252 to the second powermodule 254. The first power module 252 may include a pair of first minorsides 258 and a pair of first major sides 260. In FIGS. 5A and 5B onlyone of the pair of first minor sides 258 and one of the pair of firstmajor sides 260 is visible due to an orientation of the first powermodule 252.

The first power module 252 may include one or more first coolantchannels 261 and the second power module 254 may include one or moresecond coolant channels 262. Each of the coolant channels may be locatedadjacent heat generating components (not shown) included within arespective power module. Examples of the heat generating componentsinclude switching units or a power stage. For example, each of the oneor more first coolant channels 261 and each of the one or more secondcoolant channels 262 may be located adjacent one or more switching unitsor a power stage. In another example, a coolant cavity may be definedbetween respective pairs of coolant channels to direct coolant acrossthe heat generating component as described in relation to FIGS. 2C and2D.

The first power module 252 may further include a first upper portion 264arranged with a first lower portion 265. A rib 266 extends about aperimeter of upper portion 264 of the first power module 252. The firstupper portion 264 may define a first upper surface groove 271 spacedinward from the pair of second minor sides 272 and the pair of secondmajor sides 274. While not visible in FIGS. 5A and 5B due to anorientation of the second power module 254, the groove 278 is shown inFIG. 5C and is shaped and oriented similar to the first groove 124 ofFIG. 2A. The first lower portion 265 may include a first sidewall 269extending about the perimeter and defining a first cavity 267. The firstupper portion 264 may define a first side face 268 extending about aperimeter of the first upper portion 264. The first side face 268 may bespaced inward from planes defined by each of the pair of first minorsides 258 and the pair of first major sides 260. The first power module252 may include a first extension 270 spaced inward from the firstsidewall 269 and within the first cavity 267 as illustrated in FIG. 5C.

As mentioned above, the second power module 254 may also includefastening and alignment features to assist in securing the first powermodule 252 to the second power module 254. The second power module 254may include a pair of second minor sides 272 and a pair of second majorsides 274. In FIGS. 5A and 5B only one of the pair of second minor sides272 and one of the pair of second major sides 274 is visible due to anorientation of the second power module 254.

The second power module 254 may further include a second upper portion276 arranged with a second lower portion 277. A second groove 278extends about a perimeter of the second power module 254. The secondupper portion 276 may define a second upper surface groove 275 spacedinward from the pair of second minor sides 272 and the pair of secondmajor sides 274. While not visible in FIGS. 5A and 5B due to anorientation of the second power module 254, the second groove 278 isshown in FIG. 5C and is shaped and oriented similar to the first groove124 of FIG. 2A.

The second lower portion 277 may include a second sidewall 281 extendingabout the perimeter and defining a second cavity 279. The second upperportion 276 may define a second side face 280 extending about aperimeter of the second upper portion 276. The second side face 280 maybe spaced inward from planes defined by each of the pair of second minorsides 272 and the pair of second major sides 274. The second powermodule 254 may include a second extension 282 extending about an innerperimeter of the second lower portion 277 within the second cavity 279.

FIG. 5C is a front view, in cross-section, illustrating an example ofthe fastening features securing the first power module 252 to the secondpower module 254. In this example, the second upper portion 276 of thesecond power module 254 is disposed within the first cavity 267 of thefirst power module 252 such that the first extension 270 of the firstpower module 252 sits within the second upper surface groove 275 of thesecond power module 254 to secure the first power module 252 to thesecond power module 254. Portions of the first sidewall 269 of the firstlower portion 265 are aligned for a flush relationship with portions ofthe pair of second minor sides 272 and portions of the pair of secondmajor sides 274.

The ribs 266 and grooves 278 are arranged with one another such that oneof the one or more first coolant channels 261 and one of the one or moresecond coolant channels 262 are in substantial registration with oneanother when the first power module 252 and the second power module 254are secured to one another. The ribs 266 grooves 278 and extensions 270may also be arranged with one another to create a sealed relationshipbetween the first power module 252 and the second power module 254 suchthat coolant may flow between the one or more first coolant channels 261and the one or more second coolant channels 262 without leaking. Forexample, each of the first upper surface groove 271 and the second uppersurface groove 275 may be sized to receive a seal material therein. Theseal material may secure a respective extension within a respectivegroove to assist in preventing leakage of coolant flowing within thecoolant channels. Additionally, the grooves and extensions of each powermodule may be arranged with one another such that there are no fastenersprojecting externally from either power module. It is also contemplatedthat the sidewalls may be of a flexible material to facilitate a snapfit between the first power module 252 and the second power module 254.

It is contemplated that a third power module (not shown) may include astructural design substantially identical to one of the first powermodule 252 or the second power module 254 for securement to the firstpower module 252 or the second power module 254 in a stack. For example,the third power module may include fastening features for alignment withcorresponding fastening features of the first power module 252 or thesecond power module 254. The structural design of the power modulesprovides flexibility to utilize a number of power modules in a stackbased on vehicle power requirements, e.g. higher power requirements mayuse more than two power modules while lower power requirements may useonly two power modules.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms encompassed by the claims.The words used in the specification are words of description rather thanlimitation, and it is understood that various changes can be madewithout departing from the spirit and scope of the disclosure. Aspreviously described, the features of various embodiments can becombined to form further embodiments of the disclosure that may not beexplicitly described or illustrated. While various embodiments couldhave been described as providing advantages or being preferred overother embodiments or prior art implementations with respect to one ormore desired characteristics, those of ordinary skill in the artrecognize that one or more features or characteristics can becompromised to achieve desired overall system attributes, which dependon the specific application and implementation. These attributes caninclude, but are not limited to cost, strength, durability, life cyclecost, marketability, appearance, packaging, size, serviceability,weight, manufacturability, ease of assembly, etc. As such, embodimentsdescribed as less desirable than other embodiments or prior artimplementations with respect to one or more characteristics are notoutside the scope of the disclosure and can be desirable for particularapplications.

What is claimed is:
 1. A vehicle power module comprising: a housinghaving an upper portion defining a first cavity that encloses anelectrical component, the housing including two minor side walls and twomajor sidewalls that each have an outer surface, the outer surfaces forma continuous perimeter of the housing, wherein the two minor side wallsand the two major sidewalls each include a lower portion including anextension wall that extends from one side of the housing and extends theouter surfaces to the extension walls, the extension walls define asecond cavity having an inner surface on the opposite side of theextension walls from the outer surfaces, wherein the inner surface ofthe extension walls define a first lock feature, wherein the upperportion of the housing includes an outer wall recessed relative to theouter surfaces that is provided with a second lock feature that isreceived in the second cavity and locked to the first lock feature of anadjacent vehicle power module.
 2. The vehicle power module of claim 1wherein the first lock feature includes a groove, and the second lockfeature includes a rib, wherein the groove and the rib connect thevehicle power module to the adjacent vehicle power module.
 3. Anassembly comprising: a first power module including a first housinghaving a first upper portion defining a first cavity that encloses afirst electrical component, the first housing including two first minorside walls and two first major sidewalls that each have a first outersurface, the first outer surfaces form a first continuous perimeter ofthe first housing, wherein the two first minor side walls and the twofirst major sidewalls each include a first lower portion including afirst extension wall that extends from a first one side of the firsthousing and extends the first outer surfaces to the first extensionwalls, the first extension walls define a first receptacle cavity havinga first inner surface on an opposite side of the first extension wallsfrom the first outer surfaces, wherein the first inner surface of thefirst extension walls define a first groove, wherein the first upperportion of the first housing includes a first recessed outer wall thatis provided with a first rib; and a second power module including asecond housing having a second upper portion defining a second cavitythat encloses a second electrical component, the second housingincluding two second minor side walls and two second major sidewallsthat each have a second outer surface, the second outer surfaces form asecond continuous perimeter of the second housing, wherein the twosecond minor side walls and the two second major sidewalls each includea second lower portion including a second extension wall that extendsfrom one side of the second housing and extends the second outersurfaces to the second extension walls, the second extension wallsdefine a second receptacle cavity having a second inner surface on theopposite side of the second extension walls from the second outersurfaces, wherein the second inner surface of the second extension wallsdefine a second groove, wherein the second upper portion of the secondhousing includes a second recessed outer wall provided with a second ribthat is received in the first receptacle cavity and locked to the firstgroove of the first power module.
 4. The assembly of claim 3 furthercomprising: a sealant provided between the first groove and the firstrib.
 5. The assembly of claim 3 wherein the first power module includesa first portion of a first coolant channel and a first portion of asecond coolant channel, and wherein the second power module includes asecond portion of the first coolant channel and a second portion of thesecond coolant channel, and wherein the first portion of the firstcoolant channel and the first portion of the second coolant channel aresecured together and are in fluid communication with the second coolantchannel.
 6. The assembly of claim 5 wherein the first electricalcomponent and the second electrical component include one or moreswitching units, and wherein the first coolant channel and the secondcoolant channel circulate a coolant across the first electricalcomponent and the second electrical component.
 7. The assembly of claim3 further comprising: a coolant circulation system wherein the firstpower module and the second power module define two pairs of coolantchannels extending through the first power module and the second powermodule and are disposed within and open into a coolant cavity definedbetween the first power module and the second power module by a lowersurface of the first power module and an upper surface of the secondpower module, wherein the first extension walls extend about the coolantcavity and between the first and second power modules, and wherein thecoolant cavity provides fluid communication of coolant between the twopairs of coolant channels across electrical components disposed withinthe first power module and the second power module.